Apparatus and method for stowing utility carts

ABSTRACT

A rack for stowing wheeled utility carts may include a deck surface on which a plurality of carts may be at least partially received and a wheel stop surface adapted to engage a wheel on the carts to inhibit rolling movement of the carts. The rack may also include a plurality of support rails extending above the deck surface, a first locator carried by at least one of the support rails and adapted to facilitate positioning a separate stowage rack on top of said stowage rack, and a second locator adapted to communicate with a first locator of another stowage rack to facilitate positioning said stowage rack above another stowage rack. Accordingly, several wheeled carts can be releasably retained on the rack, and several racks can be stacked one on top of another to permit stowing a plurality of carts in a relatively small floor space or area.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority of U.S. Application No. 60/713,580, filed Sep. 1, 2005, the complete disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to stowage racks, and more particularly to stackable stowage racks that may be used for wheeled utility carts.

2. Related Art

Non-motorized wheeled utility carts are commonly used for transporting product from one place to another. A need to move large quantities of product on a regular basis typically requires a relatively large stock of utility carts. Unfortunately, having a large stock of utility carts requires a relatively large amount of space to stow the carts. Typically, the carts are stowed side-by-side at ground level, thereby occupying a maximum amount of valuable floor space, which can be costly and inefficient.

SUMMARY OF THE INVENTION

A stackable rack for stowing utility carts having a plurality of wheels may include a deck surface on which a plurality of utility carts may be at least partially received and a wheel stop surface adapted to engage a wheel on the utility carts to inhibit rolling movement of the utility carts. The rack may also include a plurality of support rails extending above the deck surface, a first locator carried by at least one of the support rails and adapted to facilitate positioning a separate stowage rack on top of said stowage rack, and a second locator adapted to communicate with a first locator of another stowage rack to facilitate positioning said stowage rack above another stowage rack. Accordingly, several wheeled carts can be releasably retained on the rack, and several racks can be stacked one on top of another to permit stowing a plurality of carts in a relatively small floor space or area.

According to a method of stowing wheeled utility carts, a plurality of stackable racks are provided with each having a deck surface and a plurality of support rails extending from said deck surface wherein the deck surface has a wheel stop surface adapted to engage a wheel on the utility carts to inhibit the utility carts from rolling movement along the deck surface. A predetermined number of utility carts are loaded onto the deck surface to bring the wheel on each of the carts into engagement with the wheel stop surface, and a fully loaded one of the racks is stacked on top of another rack.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the objects, features, and advantages of the invention will become readily apparent in view of the following detailed description of presently preferred embodiments and the best mode, appended claims and accompanying drawings, in which:

FIG. 1 is a perspective view of one embodiment of a stowage rack shown loaded with a plurality of six-wheeled utility carts;

FIG. 1A is an enlarged fragmentary view showing a center wheel of one six-wheeled utility cart received in a retention gap of the stowage rack;

FIG. 2 is view similar to FIG. 1 with the utility carts unloaded;

FIG. 3 is a perspective view of a pair of stowage racks with one stacked upon the other;

FIG. 4 is a bottom perspective view of the stowage rack;

FIG. 5 is a schematic front view of the stowage racks of FIG. 4;

FIG. 6 is an enlarged partial view of a deck surface of the encircled area 6 of FIG. 2; and

FIG. 7 is a perspective view of a stowage rack that may be used to stow six-wheeled or four-wheeled utility carts.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring in more detail to the drawings, FIG. 1 illustrates a stowage rack 10 according to one presently preferred embodiment for stowing a plurality of wheeled utility carts 12 thereon. The stowage racks 10 are adapted to be stacked one above another (FIGS. 3 and 5) while fully loaded with carts 12, thereby minimizing the square footage foot print of floor space required to stow the carts 12. In the embodiment shown, by way of example and without limitations, each rack 10 is able to maintain five standard sized six-wheeled utility carts 12 thereon in side-by-side relation, with at least five racks 10 being stackable in vertical relation on one another. Accordingly, at least twenty-five utility carts 12 can be stowed in a floor space foot print typically occupied by five carts 12. Of course, each rack may store a different number of carts, and the number of racks that may be stacked, partially nested, or otherwise arranged may vary as desired.

As shown in FIG. 1, the utility carts 12 are represented, by way of example and without limitations, as six-wheeled carts. The carts 12 generally have a rectangular load supporting surface or platform 14 extending between opposite ends 16 and are commonly equipped with upstanding, inverted, U-shaped handles 18 at each end to facilitate moving and manipulating the carts 12 by hand. The carts 12 typically have a pair of caster-type wheels 20 adjacent each of the ends 16 and a pair of fixed or fixable center wheels 22 located generally midway between the caster wheels 20. The center wheels 22 typically extend slightly further from the platform 14 than the caster wheels 20, and thus, extend lower than the front and rear wheels 20, such as by having a larger diameter or by being carried on a lowered axle. As such, the carts 12 can generally be balanced completely on the center wheels 22 while the front and rear wheels 20 remain spaced from a ground surface, as is known.

The stowage rack 10 has a generally flat deck or deck surface 24 for supporting the carts 12 thereon. The deck surface 24 is represented as being generally rectangular, for example, though it could take on other shapes, with a width extending between opposite sides 26, such as to accommodate five carts arranged in side-by-side relation, for example, and having a length extending between front and rear ends 27, 28 sufficient to accommodate the length of the carts 12. The deck surface 24 is represented here, for example, as being supported on a horizontal peripheral frame. The frame has horizontally extending front and rear supports 29, 30, defining in part the front and rear ends 27, 28 of the rack 12, with horizontally extending side supports 32 extending between the front and rear supports 29, 30. As shown in FIG. 4, a plurality of cross supports 34 preferably extend laterally between the side supports 32 to provide added support to the deck surface 24. A pair of the cross supports 34 are preferably located centrally or midway between the front and rear supports 29, 30, with the pair of cross supports 34 being spaced from one another to define a wheel engaging stop surface, referred to hereafter as retention gap or simply gap 36 (FIG. 1A). The gap 36 may be elongated and have a width less than the diameter of the center wheels 22 of the six-wheeled cart 12. As shown in FIG. 1A, the gap 36 may be sized so that when the caster wheels 20 are passed over the gap, the wheels 20 are partially received in the gap 36 with a portion of the caster wheels 20 extending below the uppermost surface of the deck surface 24. In one implementation, between about 10% an 40% of the circumference of the wheel may be received in the gap (i.e. the distance between the points of contact of the wheel with the deck surface 24 in the area of the gap 36, measured along the portion of the wheel received in the gap and not extending above the gap, is between about 10% and 40% of the circumference of the wheel). Of course, more of less of the wheel may be received in or retained by the wheel stop surface, as desired.

By way of examples, the deck surface 24 can be formed from individual strips of material laid side-by-side and resting in between or on the side supports 32 and cross supports 34, or the deck surface could be formed from wider planks or sheets of material that cover all or any portion of the total deck surface with a slot, recess or the like defining the gap 36. The deck surface material may be retained on the supports 32, 34 or otherwise carried by the frame in any suitable way, including, by way of examples without limitation, fasteners, welding, interlocking or overlapped members and adhesion.

As best shown in FIG. 6, the deck surface 24 can be constructed having a plurality of through openings 38, such as through the use of an expanded metal, a fabricated grate, or a perforate sheet of material, for example. As such, any solid debris or liquid is able to pass generally freely through the openings 38 to prevent the deck surface 24 from corroding, collecting pools of liquid, or becoming otherwise fouled or dirty, and to facilitate cleaning the racks 10.

The rack 10 has a plurality of support rails 40 extending upwardly from the deck surface 24, represented here, by way of example and without limitations, as defining a pair of front and rear comers of the rack 10. The support rails 40 may extend a predetermined distance upwardly to support an overlying rack 10 at a sufficient height to allow the upstanding handles 18 of the stowed carts 12 resting on the underlying rack 10 to be freely received beneath the deck surface 24 of the overlying rack 10. The support rails 40 are preferably braced to one another via a cross brace to add strength and rigidity to the rack 10. For example, the rear support rails 40 are braced to one another by a horizontally extending upper support or cross brace 42 and a pair of crisscrossed supports or braces 43 extending between the upper cross brace 42 and the deck surface 24; and the rear support rails 40 and a corresponding one of the front support rails 40 on the same side 26 of the deck surface 24 are braced to one another by a horizontally extending upper support or cross brace 44 and a pair of crisscrossed supports or braces 45 extending between the upper cross brace 44 and the deck surface 24.

As such, three sides (the sides 26 of the rack 10 and the rear end 28 of the rack 10) are at least partially closed-off by the corresponding crisscrossed braces 45, 43, and thus, in addition to providing added support to the support rails 40, the braces 43, 45 can act to retain the carts 12 on the rack 10 by preventing movement of the carts through these three sides. The front upright support rails 40 are preferably braced to one another by a horizontally extending upper support or cross brace 46 that is spaced a sufficient distance from the deck surface 24 to allow the upright handles 18 to pass freely there under when the carts 12 are being loaded on the rack 10 such that the front side of the rack is open to permit the carts to be loaded into and unloaded from the rack through the front side. In the implementation shown, the upper cross brace 46 is spaced further from the deck surface 24 than the other upper braces 42, 44 which may be located to engage the cart handles 18. Other retainers or support members may be provided to engage and retain a desired portion of a cart if, for example, upstanding handles like those shown at 18 are not provided at each end of the cart. For example, a cart may have a handle at only one end, and it may be desirable to provide a retainer to engage the end of the cart without a handle to more reliably retain the carts and to permit the carts to be loaded on the racks 10 with either end leading.

The upright support rails 40 are preferably equal in height to facilitate supporting an overlying rack 10 in a level orientation. Each of the support rails 40 may have a first locator and a second locator at opposite ends of the rails. One of the locators, represented here as a first or upper locator 48, is generally funnel shaped and may include an opening, while the other locator, represented here as a second or lower locator 50, is generally cylindrically shaped and adapted to be received in the opening of a first locator. The funnel shaped upper locators 48 extend upwardly from one end of the support rails 40, while the lower locators 50 extend downwardly from the other end of the support rails 40 below the deck surface 24. Each upper locator 48 of an underlying rack 10 is adapted to receive a corresponding lower locator 50 of an overlying rack 10 to facilitate stacking and maintaining the racks 10 in a secure and stationary position relative to one another. The funnel shape of the upper locators 48 facilitates guiding the lower locators 50 for receipt therein. The respective locators 48, 50 can be formed as one piece with the support rails 40, or they can be attached thereto, such as by fasteners or a weld joint, for example. It should be recognized that the locators 48, 50 could extend from a location on the racks other than the support rails 40, and that their shapes could be altered or swapped, if desired.

To facilitate moving or stacking the racks 10, a pair of fork guide members 52 can be provided. As shown in FIGS. 1-5, in one implementation, the fork guide members 52 can extend downwardly from the deck surface 24 and be spaced relative to one another for receipt of a pair of standard forks on a fork lift (not shown). The fork guide members 52 may be centrally located between the sides 26 and extend from the front end 27 toward the rear end 28 of the rack 10. As shown in FIG. 5, the fork guide members 52 are preferably attached to the cross supports 34 via a weld joint, for example, and extend downwardly therefrom a distance equal to or less than the lower locators 50 to allow the rack to rest preferably on the lower locators 50 without interference from the fork guide members 52.

As shown in FIG. 7, a utility cart stowage rack 60 constructed according to another embodiment has a deck surface 62 with a centrally located gap 64 in the deck surface, as in the embodiment above, and also at least one, and represented here as having an additional pair of gaps 66, with one gap 66 being located adjacent each the front and rear ends 27, 28. The gaps 66 may have a width less than the diameter of the front and rear wheels 20 of the six-wheeled cart 12, and less than the diameter of the wheels on a four wheeled cart (not shown). Accordingly, the gaps 66 can provide redundant restraint to the six-wheeled carts, or act to restrain on the deck surface four-wheeled carts that have front and rear pairs of wheels, but no center wheels. Other than the additional gaps 66, the rack 60 may be constructed the same as the rack 10 that was previously described.

As shown in hidden lines in FIG. 1A, one or more protrusions 36′ carried by the frame or deck surface may be provided instead of or in addition to a gap 36 in the deck surface 24. While two protrusions 36′ are shown, it may be possible to use only one protrusion 36′ that opposes movement of the carts out of the rack through the side by which the carts are loaded into and unloaded from the rack 10.

In use, the carts 12 are simply wheeled onto the deck surface 24, 62 of the respective rack 10, 60 until the associated wheels 20, 22 are received in the respective gaps 36, 64, 66 in the deck surface 24, 62, whether center wheels 22 on the six-wheeled cart 12 or at least one pair of the front or rear wheels on the four wheeled cart, as discussed above. If only four-wheeled carts are being stowed, then the rack 60 as discussed in association with FIG. 7 may be preferred. When the rack 10, 60 is loaded with carts in side-by-side orientation, the rack 10, 60 can be stowed by stacking it on top of another rack 10, 60. Preferably, the loaded rack is lifted via the fork lift and moved into position orient the lower locators 50 into vertical alignment with the upper locators 48 on the underlying cart. The raised rack is then lowered until the upper locators 48 receive the lower locators 50, thereby ensuring the racks are stacked properly and securely relative to one another. This process is repeated until the desired number of racks are filled and stacked on one another, such as about five racks high.

It should be recognized that upon reading the disclosure herein, that one ordinarily skilled in the art of would readily recognize other embodiments than those disclosed herein, with those embodiments being within the spirit and scope of the invention. For example, rather than the wheel stop surface being formed via the gap, it could be formed via one or more protrusions that may be integral with or carried by or on the deck surface, a recess or concavity, or other suitable arrangement to releasably retain or restrain the carts to at least inhibit, and preferably prohibit, the carts from unintentionally or accidentally rolling or moving out of a rack. Further, while the gaps 36, 64, 66 shown in the drawings are elongated and continuous, a plurality of discrete gaps, openings, protrusions, or other wheel stop surfaces may be provided along the deck surface or frame of the rack. Accordingly, the disclosure herein is intended to be exemplary, and not limiting. The scope of the invention is defined by the following claims. 

1. A stackable rack for stowing utility carts having a plurality of wheels, the rack comprising: a deck surface on which a plurality of utility carts may be at least partially received and having a wheel stop surface adapted to engage a wheel on said utility cart to inhibit rolling movement of the utility cart; a plurality of support rails extending upwardly relative to the deck surface; a first locator carried by at least one of the support rails and adapted to facilitate positioning a separate stowage rack on top of said stowage rack; and a second locator adapted to communicate with a first locator of another stowage rack to facilitate positioning said stowage rack above another stowage rack.
 2. The rack of claim 1 wherein said wheel stop surface is defined by a gap located in the deck surface, said gap having a width less than a diameter of a wheel for receiving a portion of the wheel therein.
 3. The rack of claim 2 wherein the deck has front and rear ends and a pair of opposed sides extending between the front and rear ends, and wherein the gap is generally equidistant between the front and rear ends.
 4. The rack of claim 2 wherein the deck has front and rear ends and a pair of opposed sides extending between the front and rear ends, and wherein said gap is disposed closer to one of the front and rear ends than the other of the ends.
 5. The rack of claim 1 further comprising a pair of fork guide members extending from the deck surface, and wherein the deck has front and rear ends and a pair of opposed sides extending between the front and rear ends, and the fork guide members are centrally located between the sides and are spaced relative to one another to receive a pair of forks on a fork lift to facilitate handling of the rack.
 6. The rack of claim 1 wherein the first and second locators are complementarily formed to provide a secure connection between them.
 7. The rack of claim 1 wherein one of the first and second locators is at least partially received in the other of the first and second locators.
 8. The rack of claim 7 wherein one of the first and second locators includes an opening and the other of the first and second locators includes a protrusion adapted to be received in an opening.
 9. The rack of claim 1 wherein the wheel stop surface includes at least one protrusion.
 10. The rack of claim 1 wherein the cart includes a frame that has four sides and supports that prevent utility carts from moving off the rack through three sides of the rack, and the frame has an open fourth side through which the carts may be loaded into and unloaded from the cart, and the wheel stop surface opposes movement of the carts through the open side.
 11. The rack of claim 1 wherein a separate second locator is provided for each support rail, a separate first locator is provided for each support rail and each first locator is adapted to communicate with a corresponding second locator of an adjacent rack when one rack is stacked on another rack.
 12. The rack of claim 1 wherein more than one wheel stop surface is provided with each wheel stop surface adapted to engage a different wheel of a utility cart.
 13. The rack of claim 12 wherein one wheel stop surface is adapted to engage a wheel adjacent to one end of a utility cart and another wheel stop surface is adapted to engage a wheel adjacent to an opposite end of the utility cart when the utility cart is fully loaded onto the rack.
 14. A rack for storing utility carts having at least one wheel, comprising: a frame having a plurality of supports that define a plurality of sides with all but one of the sides closed to movement of utility carts therethrough; a deck carried by the frame and adapted to receive a plurality of utility carts thereon; a wheel stop carried by one or both of the deck and the frame and adapted to engage at least one wheel of each cart received on the deck to inhibit movement of each cart on the deck through said one of the sides of the frame; at least one first locator carried by the frame; and at least one second locator carried by one or both of the deck and the frame and adapted to cooperate with a first locator of a second rack when the second rack is stacked on said rack.
 15. The rack of claim 14 wherein said wheel stop surface is defined by a gap located in the deck surface, said gap having a width less than a diameter of a wheel for receiving a portion of the wheel therein.
 16. The rack of claim 14 wherein the first and second locators are complementarily formed to provide a secure connection between them when a cart is stacked on another cart.
 17. The rack of claim 14 wherein the wheel stop includes at least one protrusion.
 18. The rack of claim 14 wherein the frame includes four support rails, a separate second locator is provided for each support rail, a separate first locator is provided for each support rail and each first locator is adapted to communicate with a corresponding second locator of an adjacent rack when one rack is stacked on another rack.
 19. The rack of claim 14 wherein more than one wheel stop is provided with each wheel stop surface adapted to engage a different wheel of a utility cart.
 20. A method of stowing wheeled utility carts, comprising: providing a plurality of stackable stowage racks each having a deck surface and a plurality of support rails extending from said deck surface wherein said deck surface has a wheel stop surface adapted to engage a wheel on said utility carts to inhibit said utility carts from rolling movement along said deck surface; rolling a predetermined number of said utility carts onto said deck surface to bring said wheel on each of said carts into engagement with said wheel stop surface; and stacking a fully loaded one of said stowage racks on top of another stowage rack. 